LV5012MD-A19-120VEVM05 [ For A19/E27 LED Bulb Application ] The Buck-Boost converter for phase cut dimming with High Power Factor Application Note Ver1.05 LV5012MD-A19-120VEVM05 Application Note 1. Introduction 2. Features 3. Performance Specifications 3.1. Application constitution 3.2. Electrical characteristics 4. Schematic 5. Evaluation Board 6. Test Setup 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 7.2 Equipment Shutdown 7.3 Phase Angle Decode vs LED Current (at dimming) 8. Performance Data 8.1 Efficiency 8.2 Power factor 8.3 Line regulation 8.4 Output voltage/current operation waveform (No dimming) 8.5 Input voltage/current operation waveform (No dimming) 8.6 Switching operation waveform 8.7 LED current vs Phase angle 8.8 Dimming operation waveform 8.9 EMI data 9. Board Layout 10. Bill of materials 11. Transformer specification 12. Detailed Descriptions for Application Circuit Setting 12.1 Transformer design 12.2 REF_IN pin and ALC_C pin setting 12.3 CS pin setting 12.4 ACS pin and DML pin setting 12.5 HV pin setting 12.6 Protection function 1. Introduction The LV5012MD-A19-120VEVM05 is a 11W, 120VAC non-isolated dimmable LED driver for A19 and E27 applications. The LV5012MD-A19-120VEVM05 is a Buck-Boost Converter used for commercial and residential phase-cut dimmer compatible LED lamp drivers. 2. Features ・Non-isolated Buck-Boost converter ・Compatible With Leading and Trailing Edge Dimmer ・Constant Current & High Power Factor & Improved THD ・Short Protection - [latch off] ・Over Voltage Protection -[auto recovery] ・2 Stage Thermal Protection -[auto recovery] 3. Performance Specifications 3.1. Application constitution Non-isolation Buck-Boost converter with Phase Cut Dimming 3.2. Electrical characteristics (Operating Temperature = 25C) Table1. LV5012MD-A19-120VEVM05 Electrical Performance Specifications Description Min Typ Max Units Input AC voltage 108 120 132 VAC Output voltage 60 V Output current 160 mA Efficiency 87 % Power Factor 0.94 Comment VAC=120V, 60Hz VAC=120V, 60Hz 4. Schematic AC1 F1 10/1W 6 LEDs in series, 2 parallel [LED: CREE XLamp MX-3S LEDs] 15/2W R21 1k/1W AC INPUT AC2 R23 VR1 C4 0.1uF /630V R1 15/2W C1 D1 S1ZB60 0.033uF /AC250V R2 L2 0 1.0mH LEDC3 0.33uF /450V C2 0.1uF /630V L1 0 R3 680k R7 1.0k R5 680k R8 12k 1 2 Transformer T1 specifications Inductance value 2-6 inductance L1 = 325uH Turns ratio (2-6) : (5-3) = 3.3 : 1 3 4 5 6 C5 150pF R4 5.6k R6 27k R9 0 C8 4.7uF /50V D3 R14 MMSD103 0 T1 3 OUT DML GND 6 R12 22 100k 13 VIN 12 GND CS ENB REF_IN ACS TRC ALC_C 39k 11 D4 MURS240T3G R13 14 NC 7 REF_OUT R18 5 U1 LV5012MD HV 2 C9 220uF /80V Q1 NDD03N50 R11 4.7Meg 10 9 8 C6 0.1uF C7 1uF Figure1. LV5012MD-A19-120VEVM05 Schematic R16 0.82 R17 0.82 LED+ 5. Evaluation Board LEDLED+ AC INPUT Figure2. LV5012MD-A19-120VEVM05 Transformer Side 64mm 24mm Figure3. LV5012MD-A19-120VEVM05 IC Side 6. Test Setup 6.1 Test Equipment Voltage Source: 120VAC AC source, NF EPO2000S Power Meter: HIOKI 3332 Volt Meter: ADVANTEST R6441D DIGITAL MULTIMETER AMP Meter: Agilent DIGITAL MULTIMETER 34401A Output Load: 2 Parallel of 6 LEDs series (LED: CREE XLamp MX-3S LEDs) Oscilloscope: LeCroy WaveRunner 6050A Operating Temperature: 25℃ 6.2 Recommended Test Setup Volt Meter + Power Meter AMP Meter Neutral AC Source AC INPUT LED+ LV5012MD-A19-120VEVM05 Line Dimmer Min Max At No Dimming, Connect this line LEDLEDs Figure4. LV5012MD-A19-120VEVM05 Recommended Test Set Up 6.3 List of Test Points Table2. Test Points Functions TEST POINTS NAME DESCRIPTION Neutral 120VAC neutral connection Line 120VAC line voltage LED+ LED anode connection LED- LED cathode connection 7. Test Procedure 7.1 Line/Load Regulation and Efficiency Measurement Procedure 1. Connect LV5012MD-A19-120VEVM like upper Figure4. An external LED load must be used to start up the EVM. 2. Prior to turning on the AC source, set the voltage to 120VAC. 3. Turn on the AC Source. 4. Record the output voltage readings from Volt Meter and the output current reading from AMP Meter. And Record the input power reading from Power Meter. 5. Change VAC from 108VAC to 132VAC and perform “4”. 6. Refer to Section 7.2 for shutdown procedure. 7.2 Equipment Shutdown 1. Turn off equipment. 2. Make sure capacitors are discharged. 7.3 Phase Angle Decode vs LED Current (at dimming) 1. Connect LV5012MD-A19-120VEVM like upper Figure4. An external LED load must be used to start up the EVM. 2. Prior to turning on the AC source, set the voltage to 120VAC. 3. Monitor the Dimmer output AC voltage between the neutral and the line by using the oscilloscope differential probe. 4. Turn on the AC Source. 5. Maximize the dimmer ratio. 6. Record the output voltage readings from Volt Meter and the output current reading from AMP Meter. And Record the input power reading from Power Meter. And Record the phase angle of Dimmer output reading from the oscilloscope differential probe. 7. Gradually lower the Dimming ratio and perform "6". Repeat it until the Dimming ratio is minimized. 8. Refer to Section 7.2 for shutdown procedure. 8. Performance Data 8.1 Efficiency Efficiency vs Input Voltage 92 50Hz 91 60Hz Efficiency [ % ] 90 89 88 87 86 85 84 83 82 100 110 120 130 140 Input Voltage [ VAC ] Figure5. Efficiency vs Input voltage 8.2 Power factor Power Factor vs Input Voltage 1.00 50Hz 60Hz Power Factor 0.98 0.96 0.94 0.92 0.90 0.88 0.86 100 110 120 130 Input Voltage [ VAC ] Figure6. Power factor vs Input voltage 140 8.3 Line regulation LED Current (Output current) LED Current vs Input Voltage 200 50Hz 60Hz 190 LED Current [ mA ] 180 170 160 150 140 130 120 100 110 120 130 140 Input Voltage [ VAC ] Fgure7. LED current vs Input voltage Output Voltage Output Voltage vs Input Voltage 59.0 50Hz 60Hz Output Voltage [ V ] 58.5 58.0 57.5 57.0 56.5 56.0 100 110 120 130 Input Voltage [ VAC ] Figure8. Output voltage vs Input voltage 140 8.4 Input voltage/current operation waveform (No dimming) CH1 Input voltage (VAC) [100V/div] CH4 Input current [200mA/div] 5msec/div Figure9. Input waveform 8.5 Output voltage/current operation waveform (No dimming) CH1 Output voltage [10V/div] CH4 Output current (LED current) [200mA/div] 5msec/div Figure10. Output waveform 8.6 Switching operation waveform CH1 Q1 Drain voltage [100V/div] CH4 Q1 current [500mA/div] 10usec/div Figure11. Switching operation waveform 8.7 LED Current vs Phase angle [ Measurement condition: V AC=120V, 60Hz, Dimmer= LEVITON IPI06 ] LED Current vs Phase angle 180 LED Current [mA] 160 140 120 100 80 60 40 20 0 0 20 40 60 80 100 120 140 160 180 phase angle [ deg ] Figure12. LED current vs Phase angle 8.8 Dimming operation waveform [ Measurement condition: V AC=120V, 60Hz, Dimmer= LEVITON IPI06 ] Phase angle = 120 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure13. Dimming operation waveform at phase angle=120degree Phase angle = 60 degree CH1 Input voltage =Dimmer output [100V/div] CH4 Input current [200mA/div] 5msec/div Figure14. Dimming operation waveform at phase angle=60degree 8.9 EMI data Conducted Emission QP Measurement [ Measurement condition: VAC=120V,60Hz ] Phase1 Phase2 Figure15. Conducted Emission, QP Measurement Board Layout Figure16. Transformer Side Layout Figure17. IC Side Layout Figure18. Board Size 9. Bill of materials No Designator Description Value Footprint Manufacturer Manufacturer Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 C1 C2 C3 C4 C5 C6 C7 C8 C9 D1 D3 D4 F1 L1 L2 Q1 R1 R2 R3 R4 R5 R6 R7 R8 R9 R11 R12 R13 R14 R16 R17 R18 R21 R23 T1 U1 VR1 Metallized Polyester Film Capacitor Capacitor,Ceramic,X7R Capacitor,Ceramic,X7T Capacitor,Ceramic,X7R Capacitor,Ceramic,CH Capacitor,Ceramic,X7R Capacitor,Ceramic,X7R Capacitor,Ceramic,X7R Aluminum Electrolytic Capacitor Diode,Bridge Diode Diode,Ultrafast Metal Film Fuse Resistor Jumper Power Inductor N-Channel Power MOSFET Metal Film Resistor Jumper Chip Resistor Chip Resistor Chip Resistor Chip Resistor Anti-surge Chip Resistor Anti-surge Chip Resistor Jumper Chip Resistor Chip Resistor Chip Resistor Jumper Low Ohmic Chip Resistor Low Ohmic Chip Resistor Chip Resistor Metal Film Resistor Metal Film Resistor Transformer LED Driver Varistor 0.033uF/275VAC 0.1uF/630V 0.33uF/450V 0.1uF/630V 150pF/50V 0.1uF/50V 1uF/25V 4.7uF/50V 220uF/80V 0.8A,600V 0.2A,250V 2A,400V 10,1W 0 1.0mH 500V,2.6A 15,2W 0 680k 5.6k,1% 680k 27k,1% 1.0k 12k 0 4.7Meg 100k 22 0 0.82,1% 0.82,1% 39k 1k,1W 15,2W Radial Radial Radial Radial 0603 0603 0603 1206 Radial 1Z(SMD) SOD-123 SMB Axial Radial DPAK Axial 1206 0603 1206 0603 1206 1206 0603 0603 0603 0603 0603 0805 0805 0603 Axial Axial RM6 MFP14S Radial OKAYA MURATA MURATA MURATA MURATA MURATA MURATA MURATA Rubycon SHINDENGEN ON Semiconductor ON Semiconductor Panasonic Sumida ON Semiconductor Panasonic Rohm KOA Rohm KOA Rohm Rohm KOA Panasonic KOA KOA KOA Rohm Rohm KOA Panasonic Panasonic WE-Midcom ON Semiconductor Nippon Chemi-con LE333 RDER72J104K8K1C11B RDED72W334K5B1C13B RDER72J104K8K1C11B GRM1882CH1H151JA01 GRM188R71H104KA93D GRM188R71E105KA12D GRM31CR71H475KA 80ZLJ220 S1ZB60 MMSD103T1G MURS240T3G ERQ1ABJ100 RCH895NP-102K NDD03N50Z ERG2SJ150 KTR18EZPJ684 RK73H1JTTD562 KTR18EZPJ684 RK73H1JTTD273 ESR18EZPJ102 ESR18EZPJ123 RK73Z1JTTD000 ERJ3GEYJ475V RK73B1JTTD104 RK73B1JTTD220 RK73Z1JTTD000 MCR10EZHFLR820 MCR10EZHFLR820 RK73B1JTTD393 ERG1SJ102 ERG2SJ150 750341971 Rev.01 LV5012MD TND05V-271KB AC175V 10.Transformer specification 2-6 3-5 2-6 2-5 (2-6) : (5-3) 11.Detailed Descriptions for Application Circuit Setting The LV5012MD-A19-120VEVM05 is the non-isolated buck-boost converter with phase cut dimming. The explanation of each parts of the application circuit is described in figure19. How to set this application circuit is described below. AC1 F1 10/1W R23 Snubber circuit for TRIAC dimming 15/2W R21 1k/1W AC INPUT AC2 D1 S1ZB60 VR1 C1 0.033uF /AC250V R1 L1 15/2W 0 C4 0.1uF /630V R2 L2 0 1.0mH Capacitor for smoothing output voltage LEDC3 C2 0.1uF/630V 0.33uF/450V Start up resistor for HV regulator Filter for EMI and TRIAC dimming Resistors for ALC function R3 680k R5 680k R7 1.0k R8 12k U1 LV5012MD 1 2 Resistor for bleeder current Resistors for TRIAC ON/OFF detection setting and bleeder current setting 3 4 OUT DML GND VIN GND CS ENB REF_IN ACS TRC 5 150pF R4 5.6k R6 27k R9 0 7 D3 R14 MMSD103 0 T1 ALC_C 39k 3 5 D4 6 R12 100k 13 22 4.7Meg 8 C6 C7 0.1uF 1uF Capacitor for ALC function Figure19. The description of each parts of LV5012MD-A19-120VEVM05 R16 0.82 LED+ Rectifier diode Q1 NDD03N50 R11 12 11 MURS240T3G R13 14 Power MOSFET 9 REF_OUT R18 2 10 6 C5 C9 220uF /80V Auxiliary winding for VIN supply 4.7uF /50V HV NC Transformer Capacitor for VIN supply C8 Transformer T1 specifications Inductance value 2-6 inductance L1 = 325uH Turns ratio (2-6) : (5-3) = 3.3 : 1 6 LEDs in series, 2 parallel [LED: CREE XLamp MX-3S LEDs] Filter for EMI and TRIAC dimming R17 0.82 Current sense resistor 12.1 Transformer design At first calculate the inductance “L1” which is used at Power MOSFET switching. The inductance “L1” is calculated (VAC peak) 2 × D1 2 × 0.565 L1 = 2 × POUT × f where, L1 : Inductance which is used at Power MOS switching Transformer current I1 peak Power MOSFET current Rectifier diode current VAC peak : Input peak voltage f : Switching frequency = 70k [Hz] POUT : Output power POUT = VOUT × IOUT VOUT : Output voltage (LED voltage) Time T1 IOUT : Output current (LED current) D1 : Duty of Power MOSFET ON T1 D1 = T T2 T Figure20. Transformer current T1 : Time of Power MOSFET ON LED+ T : Switching period = 1/70k [sec] Vf “D2 ” is calculated T2 I1 peak × L1 D2 = T = T × (V OUT + Vf ) where, D2 : Duty of the rectifier diode ON T2 : Time of the rectifier diode ON Vf : Forward voltage of the rectifier diode I1 peak : Peak current of L1 LED- Rectified AC voltage L1 [Turns: N1] Power MOS Drain VIN [Turns: Nd] Transformer Figure21. Transformer Turns (*Refer to section “11.3”) Confirm “I1 peak” and choose the Power MOSFET and the rectifier diode to permit it. To operate in the current discontinuous mode, decide “D1”, “D2” and “L1” by the above expressions. And also actually check that the operation with the designed transformer is the current discontinuous mode. The auxiliary winding turns Nd is calculated Nd VIN = N1 VOUT where, Nd : Turns of auxiliary winding VIN : VIN pin voltage Design the most suitable transformer depending on the necessary application specifications. 12.2 REF_IN pin and ALC_C pin setting R3, R4 setting Please set R3, R4 so that the voltage peak of the REF_IN pin is around 1.1V to 1.9V. e.g. VAC=120V → R3=680kΩ, R4=5.6kΩ REF_IN peak = (120V×√2) × 5.6k / (680k+5.6k) = 1.39V C6 setting Please connect capacitor of about 0.1uF to an ALC_C pin. By the above setting, ALC function of LV5012MD becomes effective. Thereby the application of LV5012MD can achieve good line regulation and total harmonic distortion. 12.3 CS pin setting R16, R17 setting The output power of second side is set by the current sense resistor (R16, R17) connected to CS pin. The current sense resistor is calculated, 0.141 × L1 × f 2 × POUT R16 × R17 R16 + R17 = Figure22 is the operation outline diagram. Rectified AC voltage LV5012MD inside ALC_out Auto Level Control VREF (0.45Vtyp) + CLK Q RESET L1 Q1 current ALC_out OUT VREF (0.45Vtyp) Q1 Q1 current 0.5Vtyp Reference CS T R16 R17 ON OUT (Q1 Gate) OFF Ton Toff Reference=ALC_out Reference =0.45V Figure22. Operation outline diagram (No dimming) The peak current of L1 “I1 peak” is the following expression. R16 + R17 I1 peak = R16 × R17 × 0.45 ( In the case of ALC_out > VREF(0.45V) ) Reference=ALC_out 12.4 ACS pin and DML pin setting LV5012MD contains the function for TRIAC dimming. This function is operated by setting ACS pin and DML pin. Figure23 is the outline diagram of TRIAC dimming operation. Please set the TRIAC ON/OFF threshold and the Bleeder operation threshold in tune with the characteristic of TRIAC dimmer. The TRIAC ON/OFF threshold and the Bleeder operation threshold are calculated as follow. The TRIAC ON threshold of the rectified AC is determined below. R5 + R6 Vac_triac on = × 1.7 R6 The TRIAC OFF threshold of the rectified AC is determined below. R5 + R6 Vac_triac off = × 1.3 R6 The Bleeder operation threshold of the rectified AC is determined below. R5 + R6 × 0.85 R6 Vac_bleeder = Please set R5, R6 on the basis of these expressions according to TRIAC dimmer. In addition, please set R7 between the rectified AC voltage and DML pin to satisfy the following expression. R5 + R6 × 0.85 - ( R7 × 0.02 ) < 50 [V] R6 Rectified TRIAC OUT Rectified AC voltage ACS Rectified AC voltage Bleeder current R7 1.7V DML - R5 0.85V + Auto Level Control T L1 ALC_out CLK + - Q 0.1V - 1.3V TRIAC ON OUT TRIAC OFF ALC_out Q1 RESET 1.7V R6 0.85V Built-in MOSFET for Bleeder current Bleeder MOS gate ACS 1.3V LV5012MD inside Q1 current VREF (0.45Vtyp) Q1 current + VREF (0.45Vtyp) CS R16 Reference R17 0.1V T TRIAC OFF TRIAC ON TRIAC OFF Bleeder MOS gate Bleeder MOS ON Bleeder MOS OFF Figure23. Outline diagram of TRIAC dimming operation Bleeder MOS ON 12.5 HV pin setting R8 setting LV5012MD has a high voltage regulator built-in for self-supplying from the rectified AC voltage. It outputs 12V, and thereby the circuit in the IC starts. Please connect R8=12kΩ between HV pin and the rectified AC voltage to operate HV regulator normally. 12.6 Protection function 1 2 3 4 tilte UVLO OCP OVP OTP outline Under Voltage Lock Out Over Current Protection Over Voltage Protection Over Temperature Protection monitor point VIN voltage CS voltage VIN voltage PN Junction temperature 1. UVLO(Under Voltage Lock Out) If VIN voltage is 7.3V or lower, then UVLO operates and the IC stops. When UVLO operates, the power supply current of the IC is about 80uA or lower. If VIN voltage is 9V or higher, then the IC starts switching operation. VIN voltage VIN voltage UVLOON (9Vtyp) UVLOOFF (7.3Vtyp) time Output stage on off on 2. OCP(Over Current Protection) CS pin is used to sense current in primary winding of transformer via external MOSFET.This provides an additional level of protection in the event of a fault. If the voltage of the CS pin exceeds VCSOCP(1.9Vtyp.)(A), the internal comparator will detect the event and turn off the MOSFET. The peak switch current is calculated Iocp(peak)[A] = VCSOCP[V] / Rcs[Ω] The VIN pin is pulled down to fixed level, keeping the controller latched off. The latch reset occurs when the user disconnects LED from VAC and lets the VIN falls below the VIN reset voltage,UVLOOFF(7.3Vtyp.)(B). Switching restarts when VIN rises UVLOON(9Vtyp.)(C). CS voltage A C VCSOCP(1.9Vtyp) time VIN voltage B UVLOON(9Vtyp) UVLOFF(7.3Vtyp) time Output stage on off on 3. OVP(Over Voltage Protection) If the voltage of VIN pin is higher than the internal reference voltage VINOVP(27Vtyp), switching operation is stopped. The stopping operation is kept until the voltage of VIN is lower than VINOVP(27Vtyp). If the voltage of VIN pin is lower than VINOVP(27Vtyp), the switching operation is restated. Please see OVP waveform chart. OVP VIN voltage OVP release 27Vtyp time Output stage on off on 4. OTP(Over thermal protection) LV5012MD has the gradually thermal protection system. If the junction temperature exceeds 140 degrees Celsius, 1st stage protection mode is started. At 1st stage protection mode, the internal reference level compared with CS pin voltage is set to 0.1V. And the LED current is restricted to low values (approximately 5%). If the junction temperature exceeds 155 degrees Celsius, the switching operation and startup circuit are stopped. Please see the waveform chart. 155℃ 143℃ 140℃ IC Junction Temperature 128℃ Time 100% LED Current Normal Condition Normal Condition 1st Stage Thermal Protection Normal Condition Thermal Shut Down Time Approximately 5%